General On-Site Welding
MINING & AGGREGATE WELDING SERVICES IN Johnstown, CO
Chromium carbide overlay plate carries a field of hard carbides in its welded surface, which is why it outlasts plain steel many times over in a chute, hopper, or crusher liner. Rhoades Welding provides mining and aggregate welding services in Johnstown, CO, keeping crushers, screens, conveyors, hoppers, and haul equipment running across Northern Colorado's pits and quarries. We hardface wear surfaces, rebuild liners and chutes, and repair plant steel on site so a breakdown does not cost the whole shift. Open 24/7, we answer when a plant goes quiet mid-run, and our mobile truck reaches operations the Front Range and into southern Wyoming.
A STOPPED CRUSHER BACKS UP THE ENTIRE OPERATION.
When a liner wears through, a chute cracks, or a conveyor frame fails, the loss is more than one broken part. Feed backs up, trucks wait, and crews stand idle while abrasive rock sits unprocessed. Hauling plant steel to a shop adds days a working pit cannot spare, so the repair has to come to the plant.
We prioritize the fix that gets the line moving again, then recommend the hardfacing or reinforcement that keeps the same part from wearing out as fast next time. That approach turns a repeat headache into a part you stop worrying about.
- Hardfacing and wear-plate overlays
- Crusher, screen, and chute repair
- Conveyor structure and frame welding
- On-site plant maintenance welding
MINING SERVICES
WEAR WORK THAT KEEPS NORTHERN COLORADO PITS RUNNING.
Aggregate and mineral plants move tons of abrasive material every hour, and that constant grinding eats liners, chutes, screen frames, and conveyor steel. We apply hardfacing and overlay plate where abrasion hits hardest, rebuild worn chutes and hoppers, and repair cracked plant structure with the preheat and filler the steel requires. Each repair is built to take the next run, not just to close the current gap in the schedule.
SUITED TO FRONT RANGE AGGREGATE AND MINERAL SITES.
The pits, quarries, and sand and gravel operations across the Front Range run hard through the building season and into frozen winter ground. Cold steel and worn, work-hardened surfaces both demand careful heat control, so we preheat and match technique to the material and the weather. Our mobile setup reaches remote pits and plant yards across Northern Colorado and southern Wyoming, so a down crusher does not sit waiting on an outside shop.
WE FIX THE WEAR AND THE REASON IT WORE OUT.
A chute that wears through in the same spot every few months is telling you something, and simply welding it back rarely ends the cycle. Across 6 years of repair work in Northern Colorado, our owner has learned to read where and why plant steel fails, then add overlay, change the wear path, or reinforce the structure so the fix lasts. You get honest recommendations and metal that stays in service. Have a part that keeps wearing out on you?
WHAT HARDFACING AND PLANT WELDING DELIVER
Longer Wear Life
Hardfacing and overlay plate add a hard, abrasion-resistant surface where rock grinds hardest. Liners, chutes, and edges last far longer, stretching the time between rebuilds and cutting how often parts get replaced.
Less Plant Downtime
On-site repairs skip the hauling and the shop wait, so crushers, screens, and conveyors return to the line sooner. Scheduled work fits around your run instead of taking the whole day.
Lower Replacement Costs
Rebuilding a worn chute, liner, or screen frame costs a fraction of buying new. You keep plant components you already know working, spending only on the surfaces that actually wore out.
Repairs Done On Site
Our mobile truck brings welding power, tools, and plate to the pit. Most hardfacing, liner, and structural repairs happen right at the plant, so heavy steel never has to leave the yard.
Safer Equipment
Cracked frames, worn guards, and failing structure put crews and machines at risk. Timely repairs remove those hazards before a small defect turns into a failure in the middle of a shift.
Fewer Repeat Failures
Reinforcing the spots that keep cracking and overlaying the surfaces that keep wearing breaks the cycle of repeat repairs. Maintenance becomes planned and predictable instead of rushed and reactive.
WHAT WE REPAIR
OUR MINING WELDING WORK
From a worn crusher liner to a cracked conveyor frame, these are the mining and aggregate welding services operators across Northern Colorado bring to us most often.
CRUSHERS & SCREENS
Crusher & Screen Plant Repair
Worn jaw and cone components, cracked frames, and damaged screen decks are repaired and reinforced to keep the plant crushing. We weld and rebuild the steel around the wear parts to hold alignment.
HARDFACING
Hardfacing & Wear Plate
Overlay and hardfacing go on buckets, chutes, liners, and edges that face constant abrasion. The hard surface resists gravel, sand, and rock far longer than plain steel, extending the life of every part it covers.
CHUTES & HOPPERS
Chute, Hopper & Bin Repair
Transfer chutes, hoppers, and bins wear thin and crack where material flow hits hardest. We rebuild worn sections, line them with wear plate, and reshape flow paths so they last through more tons.
CONVEYORS
Conveyor Structure & Frame Welding
Conveyor frames, supports, and idler brackets crack under load and vibration. We repair and reinforce the structure in place, keeping the belt running true without pulling the whole system apart.
HAUL EQUIPMENT
Haul Truck & Loader Repair
Cracked beds, worn buckets, and broken frames on haul trucks and loaders cost production every hour they sit. We weld, hardface, and rebuild wear surfaces in the yard to get machines back to work.
PLANT MAINTENANCE
On-Site Plant Maintenance Welding
Scheduled inspection and touch-up welding catch cracks and wear while they are still small. Pits and quarries use this service to head off breakdowns during the busiest stretches of the season.
THE WORD ON OUR WORK
WHAT OUR CLIENTS SAY.
Plant operators and pit managers tend to highlight how fast we reached the site and how long the hardfacing held under abrasive material. Their reviews describe the practical, no-nonsense approach we take to keeping a plant running through the season.
Common qUESTIONs
frequently asked
questions.
Plant operators ask practical questions about wear, hardfacing, scheduling, and on-site work before a repair. These answers cover what Northern Colorado mining and aggregate customers most want to know.
What is hardfacing and where does it help most?
Hardfacing is a wear-resistant weld overlay applied to surfaces that face constant abrasion. It pays off on crusher liners, chutes, screen components, and bucket edges, where plain steel wears out quickly under rock and gravel.
Can you repair a crusher or screen plant on site?
Often, yes. Most liner, frame, and deck repairs are handled right at the plant with our mobile equipment. Heavy or precision rebuilds may be better done in the shop, and we tell you which makes sense.
How long does a hardfaced liner or chute last?
It depends on the material processed and the overlay used, but a properly hardfaced surface typically runs many times longer than bare steel. We match the overlay to the abrasion so the part earns its downtime back.
Do you work with AR plate and overlay plate?
Yes. We weld and install abrasion-resistant plate and chromium carbide overlay plate, using preheat where the steel requires it. Matching the plate and the welding process to the wear keeps the repair from cracking early.
Which wear parts can be rebuilt instead of replaced?
Chutes, liners, hoppers, bucket edges, and screen frames can usually be rebuilt when the base structure is still sound. We assess each part and rebuild where it saves money, and recommend replacement when it does not.
Can conveyor structure and frames be welded in place?
Usually, yes. Frames, supports, and brackets can be repaired and reinforced on the structure without dismantling the whole system. We shore and stabilize as needed so the belt line stays aligned after the weld.
Does Rhoades Welding service remote pits and quarries?
Yes. Rhoades Welding brings a mobile welding truck to pits, quarries, and plant yards across Northern Colorado and into southern Wyoming, handling hardfacing and repairs far from paved roads and shop doors.
Why do plant operators call Rhoades Welding?
Operators near Johnstown, CO, call Rhoades Welding because the owner brings 6 years of abrasion and repair work, answers 24/7, and fixes both the worn part and the reason it wore out.
HOW WE WORK
FROM DOWN PLANT TO BACK IN PRODUCTION, HERE IS HOW.
STEP 01
WE GET THE CALL
You describe what failed, the plant or machine involved, and the location, with photos when possible. That information helps us bring the right plate, overlay, and filler on the first trip to the pit.
STEP 02
WE ASSESS THE WEAR
We examine the worn or cracked area, check surrounding steel, and identify the material. Then we explain whether a rebuild and overlay will hold or whether a component needs replacement for a lasting fix.
STEP 03
WE PLAN AROUND YOUR RUN
We set a time that fits your production, whether that is a shift break, a weekend, or a planned shutdown. Urgent breakdowns get priority, with round-the-clock response when a plant stops mid-run.
STEP 04
WE PREP AND PREHEAT
Cracks are ground out, worn surfaces are cleaned, and rock, grease, and rust are removed. Hardened and work-hardened steel is preheated so the new weld and overlay bond fully without hidden cracks.
STEP 05
WE WELD AND OVERLAY
We weld the repair with the right process and filler, then apply hardfacing or wear plate where abrasion hits hardest. Each pass is cleaned before the next so the finished surface holds together under load.
STEP 06
WE CHECK AND ADVISE
Finished welds are inspected, moving parts are checked for fit, and the equipment is ready to run. We point out other wear areas worth watching and suggest intervals so the next repair is planned, not forced.